US7943079B2ExpiredUtilityA1

Methods of making orthodontic appliances

93
Assignee: ALIGN TECHNOLOGY INCPriority: Oct 12, 2004Filed: Nov 18, 2009Granted: May 17, 2011
Est. expiryOct 12, 2024(expired)· nominal 20-yr term from priority
Inventors:Joseph M. DesimoneRobert E. Tricca
A61C 7/08C08F 2/46
93
PatentIndex Score
27
Cited by
9
References
85
Claims

Abstract

Methods of making a removable dental positioning appliance include forming a sheet of transparent crystalline polymeric material into a shell having cavities shaped to receive and reposition teeth from a first orientation to a successive orientation. The polymeric material may then be annealed at a temperature above its glass transition temperature or cured if a curable material to enhance characteristics of the polymeric material. The polymeric material may be coated with a second transparent material.

Claims

exact text as granted — not AI-modified
1. A method of making a removable dental positioning appliance, comprising:
 forming a sheet of transparent polymeric material into a shell having cavities shaped to receive and reposition teeth from a first orientation to a successive orientation, wherein the transparent polymeric material comprises inorganic filler material selected from the group consisting of metal oxides, oxygenates, carbonates, halides, and sulfates; and 
 annealing the shell at a temperature above a glass transition temperature of the transparent polymeric material. 
 
     
     
       2. The method of  claim 1 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively densify the amorphous polymeric material. 
     
     
       3. The method of  claim 1 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively crystallize the amorphous polymeric material. 
     
     
       4. The method of  claim 1 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively decrease stress in the semi-crystalline polymeric material. 
     
     
       5. The method of  claim 1 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively enhance crystallization of the semi-crystalline polymeric material. 
     
     
       6. The method of  claim 1 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively densify the semi-crystalline polymeric material. 
     
     
       7. The method of  claim 1 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively increase or decrease the modulus of the semi-crystalline polymeric material. 
     
     
       8. The method of  claim 1 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 6,000 psi, an elongation at yield of greater than 4%, an elongation at break of greater than 80%, a tensile modulus greater than 200,000 psi, a flexural modulus greater than 200,000 psi, stress relaxation over time of not more than 50%, and a transmissivity of light between 400 nm and 800 nm greater than 75%. 
     
     
       9. The method of  claim 1 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 8,800 psi, an elongation at yield of greater than 5%, an elongation at break of greater than 100%, a tensile modulus greater than 300,000 psi, a flexural modulus greater than 330,000 psi, stress relaxation over time of not more than 30%, and a transmissivity of light between 400 nm and 800 nm greater than 80%. 
     
     
       10. The method of  claim 1 , wherein annealing is performed at a temperature between the glass transition temperature of the transparent polymeric material and the melting temperature of the transparent polymeric material. 
     
     
       11. The method of  claim 1 , wherein annealing is performed for at least about one minute. 
     
     
       12. The method of  claim 1 , wherein the transparent polymeric material comprises styrenic polymer material. 
     
     
       13. The method of  claim 1 , wherein the transparent polymeric material comprises ultra-high molecular weight polymers. 
     
     
       14. The method of  claim 1 , wherein the transparent polymeric material comprises styrenic polymeric material selected from the group consisting of acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), and styrene block copolymers (SBC). 
     
     
       15. The method of  claim 1 , wherein the transparent polymeric material comprises ion-containing polymers. 
     
     
       16. The method of  claim 1 , wherein annealing is performed only on a selected portion of the shell. 
     
     
       17. A method of making a removable dental positioning appliance, comprising:
 forming a sheet of transparent polymeric material into a shell having cavities shaped to receive and reposition teeth from a first orientation to a successive orientation, wherein the transparent polymeric material comprises organic filler material selected from the group consisting of waxes and oligomeric polymers; and 
 annealing the shell at a temperature above a glass transition temperature of the transparent polymeric material. 
 
     
     
       18. The method of  claim 17 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively densify the amorphous polymeric material. 
     
     
       19. The method of  claim 17 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively crystallize the amorphous polymeric material. 
     
     
       20. The method of  claim 17 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively decrease stress in the semi-crystalline polymeric material. 
     
     
       21. The method of  claim 17 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively enhance crystallization of the semi-crystalline polymeric material. 
     
     
       22. The method of  claim 17 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively densify the semi-crystalline polymeric material. 
     
     
       23. The method of  claim 17 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively increase or decrease the modulus of the semi-crystalline polymeric material. 
     
     
       24. The method of  claim 17 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 6,000 psi, an elongation at yield of greater than 4%, an elongation at break of greater than 80%, a tensile modulus greater than 200,000 psi, a flexural modulus greater than 200,000 psi, stress relaxation over time of not more than 50%, and a transmissivity of light between 400 nm and 800 nm greater than 75%. 
     
     
       25. The method of  claim 17 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 8,800 psi, an elongation at yield of greater than 5%, an elongation at break of greater than 100%, a tensile modulus greater than 300,000 psi, a flexural modulus greater than 330,000 psi, stress relaxation over time of not more than 30%, and a transmissivity of light between 400 nm and 800 nm greater than 80%. 
     
     
       26. The method of  claim 17 , wherein annealing is performed at a temperature between the glass transition temperature of the transparent polymeric material and the melting temperature of the transparent polymeric material. 
     
     
       27. The method of  claim 17 , wherein annealing is performed for at least about one minute. 
     
     
       28. The method of  claim 17 , wherein the transparent polymeric material comprises styrenic polymeric material. 
     
     
       29. The method of  claim 17 , wherein the transparent polymeric material comprises ultra-high molecular weight polymers. 
     
     
       30. The method of  claim 17 , wherein the transparent polymeric material comprises styrenic polymeric material selected from the group consisting of acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), and styrene block copolymers (SBC). 
     
     
       31. The method of  claim 17 , wherein the transparent polymeric material comprises ion-containing polymers. 
     
     
       32. The method of  claim 17 , wherein annealing is performed only on a selected portion of the shell. 
     
     
       33. A method of making a removable dental positioning appliance, comprising:
 forming a sheet of transparent polymeric material into a shell having cavities shaped to receive and reposition teeth from a first orientation to a successive orientation, wherein the transparent polymeric material comprises ultra-high molecular weight polymers; and 
 annealing the shell at a temperature above a glass transition temperature of the transparent polymeric material. 
 
     
     
       34. The method of  claim 33 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively densify the amorphous polymeric material. 
     
     
       35. The method of  claim 33 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively crystallize the amorphous polymeric material. 
     
     
       36. The method of  claim 33  wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively decrease stress in the semi-crystalline polymeric material. 
     
     
       37. The method of  claim 33 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively enhance crystallization of the semi-crystalline polymeric material. 
     
     
       38. The method of  claim 33 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively densify the semi-crystalline polymeric material. 
     
     
       39. The method of  claim 33 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively increase or decrease the modulus of the semi-crystalline polymeric material. 
     
     
       40. The method of  claim 33 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 6,000 psi, an elongation at yield of greater than 4%, an elongation at break of greater than 80%, a tensile modulus greater than 200,000 psi, a flexural modulus greater than 200,000 psi, stress relaxation over time of not more than 50%, and a transmissivity of light between 400 nm and 800 nm greater than 75%. 
     
     
       41. The method of  claim 33 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 8,800 psi, an elongation at yield of greater than 5%, an elongation at break of greater than 100%, a tensile modulus greater than 300,000 psi, a flexural modulus greater than 330,000 psi, stress relaxation over time of not more than 30%, and a transmissivity of light between 400 nm and 800 nm greater than 80%. 
     
     
       42. The method of  claim 33 , wherein annealing is performed at a temperature between the glass transition temperature of the transparent polymeric material and the melting temperature of the transparent polymeric material. 
     
     
       43. The method of  claim 33 , wherein annealing is performed for at least about one minute. 
     
     
       44. The method of  claim 33 , wherein the transparent polymeric material comprises styrenic polymeric material. 
     
     
       45. The method of  claim 33 , wherein the transparent polymeric material comprises filler material selected from the group consisting of inorganic materials and organic materials. 
     
     
       46. The method of  claim 33 , wherein the transparent polymeric material comprises inorganic filler material selected from the group consisting of metal oxides, oxygenates, carbonates, halides, and sulfates. 
     
     
       47. The method of  claim 33 , wherein the transparent polymeric material comprises organic filler material selected from the group consisting of waxes and oligomeric polymers. 
     
     
       48. The method of  claim 33 , wherein the transparent polymeric material comprises styrenic polymeric material selected from the group consisting of acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), and styrene block copolymers (SBC). 
     
     
       49. The method of  claim 33 , wherein the transparent polymeric material comprises ion-containing polymeric resin. 
     
     
       50. The method of  claim 34 , wherein annealing is performed only on a selected portion of the shell. 
     
     
       51. A method of making a removable dental positioning appliance, comprising:
 forming a sheet of transparent polymeric material into a shell having cavities shaped to receive and reposition teeth from a first orientation to a successive orientation, wherein the transparent polymeric material comprises styrenic polymeric material; and 
 annealing the shell at a temperature above a glass transition temperature of the transparent polymeric material. 
 
     
     
       52. The method of  claim 51 , wherein the transparent polymeric material comprises styrenic polymeric material selected from the group consisting of acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), and styrene block copolymers (SBC). 
     
     
       53. The method of  claim 51 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively densify the amorphous polymeric material. 
     
     
       54. The method of  claim 51 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively crystallize the amorphous polymeric material. 
     
     
       55. The method of  claim 51 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively decrease stress in the semi-crystalline polymeric material. 
     
     
       56. The method of  claim 51 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively enhance crystallization of the semi-crystalline polymeric material. 
     
     
       57. The method of  claim 51 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively densify the semi-crystalline polymeric material. 
     
     
       58. The method of  claim 51 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively increase or decrease the modulus of the semi-crystalline polymeric material. 
     
     
       59. The method of  claim 51 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 6,000 psi, an elongation at yield of greater than 4%, an elongation at break of greater than 80%, a tensile modulus greater than 200,000 psi, a flexural modulus greater than 200,000 psi, stress relaxation over time of not more than 50%, and a transmissivity of light between 400 nm and 800 nm greater than 75%. 
     
     
       60. The method of  claim 51 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 8,800 psi, an elongation at yield of greater than 5%, an elongation at break of greater than 100%, a tensile modulus greater than 300,000 psi, a flexural modulus greater than 330,000 psi, stress relaxation over time of not more than 30%, and a transmissivity of light between 400 nm and 800 nm greater than 80%. 
     
     
       61. The method of  claim 51 , wherein annealing is performed at a temperature between the glass transition temperature of the transparent polymeric material and the melting temperature of the transparent polymeric material. 
     
     
       62. The method of  claim 51 , wherein annealing is performed for at least about one minute. 
     
     
       63. The method of  claim 51 , wherein the transparent polymeric material comprises filler material selected from the group consisting of inorganic materials and organic materials. 
     
     
       64. The method of  claim 51 , wherein the transparent polymeric material comprises inorganic filler material selected from the group consisting of metal oxides, oxygenates, carbonates, halides, and sulfates. 
     
     
       65. The method of  claim 51 , wherein the transparent polymeric material comprises organic filler material selected from the group consisting of waxes and oligomeric polymers. 
     
     
       66. The method of  claim 51 , wherein the transparent polymeric material comprises ultra-high molecular weight polymers. 
     
     
       67. The method of  claim 51 , wherein the transparent polymeric material comprises ion-containing polymeric resin. 
     
     
       68. The method of  claim 51 , wherein annealing is performed only on a selected portion of the shell. 
     
     
       69. A method of making a removable dental positioning appliance, comprising:
 forming a sheet of transparent polymeric material into a shell having cavities shaped to receive and reposition teeth from a first orientation to a successive orientation, wherein the transparent polymeric material comprises ion-containing polymers; and 
 annealing the shell at a temperature above a glass transition temperature of the transparent polymeric material. 
 
     
     
       70. The method of  claim 69 , wherein the transparent polymeric material comprises styrenic polymeric material selected from the group consisting of acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), and styrene block copolymers (SBC). 
     
     
       71. The method of  claim 69 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively densify the amorphous polymeric material. 
     
     
       72. The method of  claim 69 , wherein the transparent polymeric material comprises amorphous polymeric material and wherein annealing the shell comprises heating the amorphous polymeric material to a temperature above a glass transition temperature of the amorphous polymeric material for a period of time sufficient to selectively crystallize the amorphous polymeric material. 
     
     
       73. The method of  claim 69 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively decrease stress in the semi-crystalline polymeric material. 
     
     
       74. The method of  claim 69 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively enhance crystallization of the semi-crystalline polymeric material. 
     
     
       75. The method of  claim 69 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively densify the semi-crystalline polymeric material. 
     
     
       76. The method of  claim 69 , wherein the transparent polymeric material comprises semi-crystalline polymeric material and wherein annealing the shell comprises heating the semi-crystalline polymeric material to a temperature above a glass transition temperature of the semi-crystalline polymeric material for a period of time sufficient to selectively increase or decrease the modulus of the semi-crystalline polymeric material. 
     
     
       77. The method of  claim 69 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 6,000 psi, an elongation at yield of greater than 4%, an elongation at break of greater than 80%, a tensile modulus greater than 200,000 psi, a flexural modulus greater than 200,000 psi, stress relaxation over time of not more than 50%, and a transmissivity of light between 400 nm and 800 nm greater than 75%. 
     
     
       78. The method of  claim 69 , wherein the shell is annealed such that the transparent polymeric material has a tensile strength at yield of greater than 8,800 psi, an elongation at yield of greater than 5%, an elongation at break of greater than 100%, a tensile modulus greater than 300,000 psi, a flexural modulus greater than 330,000 psi, stress relaxation over time of not more than 30%, and a transmissivity of light between 400 nm and 800 nm greater than 80%. 
     
     
       79. The method of  claim 69 , wherein annealing is performed at a temperature between the glass transition temperature of the transparent polymeric material and the melting temperature of the transparent polymeric material. 
     
     
       80. The method of  claim 69 , wherein annealing is performed for at least about one minute. 
     
     
       81. The method of  claim 69 , wherein the transparent polymeric material comprises filler material selected from the group consisting of inorganic materials and organic materials. 
     
     
       82. The method of  claim 69 , wherein the transparent polymeric material comprises inorganic filler material selected from the group consisting of metal oxides, oxygenates, carbonates, halides, and sulfates. 
     
     
       83. The method of  claim 69 , wherein the transparent polymeric material comprises organic filler material selected from the group consisting of waxes and oligomeric polymers. 
     
     
       84. The method of  claim 69 , wherein the transparent polymeric material comprises ultra-high molecular weight polymers. 
     
     
       85. The method of  claim 69 , wherein annealing is performed only on a selected portion of the shell.

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